Technical Service Bulletin May 2017 TSB352.02

HYDRAcube Assembly Instructions

This Technical Service Bulletin provides information required to assemble a HYDRAcube.

General Guidelines and Rack Design

The following rules are applicable to assemble a HYDRAcube:

1. The modules can ONLY be installed vertically. Each cube header has 6 connection

points for air, feed/concentrate, and filtrate (see Figure 1).

Figure 1: HYDRAcube Components

2. Feed water should enter the bottom of the module through the feed header and

filtrate will exit through the two filtrate headers on the opposite end (see Figure 2).

Component Name

1 Cube Headers

2 HYDRAcap MAX Modules

3 Sanitary Clamps and Gaskets

4 Row End Plugs

5 Row End Adaptors

6 Frame

5

6

2

3 1

4

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Figure 2: HYDRAcube Flow Path

Component Name Quantity

1 Feed/Drain Row End Adaptor (6”) 3

2 Feed/Drain Row End Plug 6” 1

3 Filtrate Row End Adaptors (6”) 2

4 Filtrate Row End Plugs 4” 2

5 Air Row End Adaptor (2”) 1 or 2*

6 Air Row End Plug 2” 2 or 3*

*If 6 or less modules, 1 air row end adaptor is required. If more than 6 modules are on the frame, 2

row end adaptors will be provided.

3. The modules will sit on the frame(s) that is provided with each HYDRAcube system.

Up to 4 modules may sit on each frame. Exception: Frames for containerized

systems (e.g. 2x7 and 2x17).

4. Connections from plant headers to HYDRAcube system should be made to the row

end adaptors that are provided with each system. Blinds are provided for all other

unused connections. See Figure 2 for a list of HYDRAcube skid components.

AIR

FEED

FILTRATE

FILTRATE

CONCENTRATE

DRAIN

5 or 6

5

1 1

1 2

4

4

6 6

3

3

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5. HYDRAcap MAX modules are preserved in a solution of 30.0% w/v calcium

chloride. This solution is relatively non hazardous, with NFPA ratings of the

following:

Health ………… 1

Fire ………... 0

Reactivity … 0

When the end caps are removed from the modules, 1.5 – 2.5 L (0.4 – 0.7 gal) of this

solution will drain, depending on the module size. If the modules are to be

subsequently shipped, they must be re-preserved according to Hydranautics

TSB331.

CAUTION: 30% CALCIUM CHLORIDE IS CORROSIVE TO METALS. RINSE

ANY SOLUTION OFF FRAMES TO AVOID CORROSION.

Assembly Procedure

The following is the recommended assembly procedure for a HYDRAcube system:

1. Prior to module installation, clean the system and its piping sufficiently to

prevent foreign matter from entering the modules, according to TSB 341.

2. HYDRAcap® MAX modules are shipped from the factory with a preservative

solution. This solution may need to be flushed or collected for disposal

(depending on local safety and environmental regulations) prior to installing the

cube headers and modules on the frame to avoid corrosion of metallic parts on

the UF rack. If required, flush each module with permeate or city water using

a hose placed in the concentrate adaptor at a rate of 2 gpm/module to the

filtrate side and 18 gpm/module to the feed side for 0.5 – 1 hour. The maximum

feed pressure allowed is 58 psig (4 bar) at 68°F (20°C).

CAUTION: 30% CALCIUM CHLORIDE IS CORROSIVE TO METALS. RINSE

ANY SOLUTION OFF FRAMES TO AVOID CORROSION.

3. While the modules are being flushed, bolt the support structure(s)/frame(s) to

ground in desired position. The distance between each frame should be

maintained at 5.6” (142 mm). A spacing bar is provided to be bolted on each

frame. See Figure 3 below. Furthermore, the level needs to be maintained

from frame to frame. Frames should be perfectly level. Failure to level frames

may make HYDRAcube assembly impossible.

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Figure 3: Example of spacing bar setup.

4. Once frames are in place, all Cube Headers for the bottom row can be

assembled.

a) Sit one header on its side on a flat surface such that the the header

is resting on the 4” and 6” header openings, as shown in Figure 4. If

sitting on other side, it will be resting on 2” and header will be tilted.

Clean off all gasket seating surfaces. NOTE: Do not damage the

gasket seating area while resting the module on its side.

Figure 4: Cube header sitting on side on 4” and 6” headers.

b) Next place the gaskets for the 2”, 4”, and 6” and place a second

header on top, lining up the gasket grooves from each header to fit

over the gaskets. See Figure 5.

CAUTION: CHECK GASKET CONDITIONS BEFORE INSTALLATION. DO NOT

DAMAGE GASKETS WHILE INSTALLING 2ND HEADER ON TOP.

Spacing Bar

Gasket seating surface

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Figure 5a: Picture on left with no gaskets, picture on right with gaskets

Figure 5b: Cube header being placed one on top of the other.

Figure 5c: Headers lined up and gaskets sitting within the grooves of the gasket sitting area.

c) Once headers are sitting in place, secure 6” clamp first. It is best to

slide the clamp between the 2” and 6” headers and rotate the clamp

around to fit the 6” clamp. See Figure 6. Repeat for the 4” and 2”

clamp, while making sure that the modules and gaskets are still in

line.

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Figure 6a: Installing 6” clamp.

Figure 6b: Installing 4” (above) and 2” (below) clamps.

d) Tighten all clamps. To expedite assembly, Hydranautics

recommends using a universal wing nut socket or Gator Grip. These

tools will also help to ensure the clamps are tightened properly. See

Figure 7.

Figure 7: Universal wing nut socket or Gator Grip

e) Continue this process for all headers. NOTE: It may be best to

connect 2 headers at a time. This way you can connect the first 2

header assembly to the next 2 header assembly (see Figure 8).

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PRECAUTION: Each header weighs 22 lbs (10 kg) not including the

clamps. Please plan accordingly and observe proper lifting

techniques when lifting multiple Cube Headers.

SAFETY NOTE: WHILE STACKING HEADERS, ENSURE HEADERS DO NOT

TIP OVER.

CAUTION: WHEN LIFTING ENDS OF HEADERS, ENSURE THE MIDDLE OF

THE HEADERS DO NOT BOW AND CREATE STRESS ON THE SANITARY

CLAMPS WHILE LIFTING. PICK UP ROW WITH LIFTING POINTS AT LEAST

EVERY 3 CUBE HEADERS. ALSO, DO NOT PUT EXCESSIVE WEIGHT OR

DAMAGE HEADERS BY MISHANDLING AND DROPPING THE HEADERS.

Figure 8: 2 connected headers placed on top of 2 other connected headers.

f) If more than 6 – 7 modules are required to be connected and no

mechanical lifting device is available, it is recommended to create

two equal banks and lay both modules horizontally and join the two

banks in the middle. You will need to make this connection on the

frame that is already in place. Blocks may be used if Hydranautics

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provided frame is not utilized to allow for spacing below header to

install the sanitary clamp, see Figure 9.

Figure 9: Example of blocks under headers when adjoining horizontally or place on frame.

g) To hold gaskets in place while joining banks of Cube Headers, place

silicone based lubricant on 4 spots of each gasket seating area, as

shown in Figure 10, to act as “glue”.

Figure 10: Silicone based lubricant placed on gasket seating surface as shown on left picture.

h) Carefully align the 2 banks of headers and join the headers together.

Ensure gaskets are in correct position. See Figure 11.

Lubricant

Gasket

sitting

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Figure 11: 2 banks of headers aligned. Gaskets in place when headers joined.

i) Once all headers for the bottom are connected, it should be placed

on the frame. Slide the back end in first. Then place front fixing bar

in front and bolt down to the frame with 2 bolts provided. Ensure

proper positioning of modules on the frame. The clamps are

positioned between the large slits within frame for better access if

necessary to disconnect a clamp. See Figure 12a. You will note that

the modules on the bottom of the frame should have no adaptors

installed as shown in Figure 12b.

Figure 12a: Back angle brace on frame shown on left. Clamp position and front brace shown on right.

Back angle brace on frame

Clamps positioned between

large slits of the frame

Front fixing bar

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Figure 12b: Bottom headers with no adaptors installed.

5. Once the headers are in place, the modules will need to be installed into each

header one by one.

a) To first prepare the modules, after the modules have been flushed of

preservative and drained the end caps must be first removed. To

remove the end caps, view the “To Dismantle Module” section in TSB

336 and follow steps 6 – 12. It is possible to leave one bolt and nut

on while removing the clamp, but loosen as much as possible to

facilitate assembling the clamp on to the cube header.

b) Thoroughly clean all surfaces that contact the o-ring on both the module and adaptors.

c) Visually check all o-rings for damage. If required, replace damaged

o-rings. NOTE: Large o-rings on the module/header interface when stretched will roll and pinch easier and thus should be changed out.

d) Apply a thin layer of silicon based lubricant over all o-ring surfaces.

CAUTION: DO NOT USE PETROLEUM OR OIL BASED LUBRICANTS.

e) Engage feed end adaptor into the air inlet of the diffuser as shown in Figure 13 and note the position of the air inlet on the feed end adaptor. This will be crucial to note when sliding on to the cube header.

No adaptor

installed

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Figure 13: Feed adaptor and diffuser connection points.

f) Once the feed adaptor is properly installed into the diffuser on the

module, the air inlet must be oriented properly into the cube header. You can see in Figure 14a the opening in the header for the air inlet. The feed adaptor shall be oriented such that the air inlet hole is facing the opening of the air inlet header as shown in Figure 14b.

Figure 14a: Feed adaptor and diffuser connection points.

Figure 14b: Air inlet on feed adaptor orientation respective to air inlet header.

Air Inlet

Diffuser connection

Air Inlet Header opening shown

by light

No opening on other side

Front of Cube

Back of Cube

Air inlet should face front of

system

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g) Lift the module and slide module with feed adaptor into module taking note of the orientation of the air inlet hole on the feed adaptor as shown in Figure 14b. Using a lifting device to lift modules into Cube Headers, see Figure 15. Contact Hydranautics for other recommended lifting devices if necessary.

Figure 15: Example of strap to lift module.

SAFETY NOTE: MAKE SURE TO AVOID PINCHING FINGERS OR HANDS BY

KEEPING HAND CLEAR WHEN POSSIBLE FROM BETWEEN MODULE AND

HEADER AS HEADER MAY FALL AT ANY TIME.

h) When sliding module into header, the header will eventually sit on the large o-ring of the module. Ensure lubricant has been applied on the large o-ring and push module into header with even pressure around the module such that the o-ring does not roll and pinch. A pinched or rolled o-ring can potentially cause a leak and require the module to be removed and o-ring replaced. See example in Figure 16. CAUTION: DO NOT ROTATE HEADER ON FEED SIDE ONCE INSTALLED

Figure 16: Example of module sitting on o-ring, module sitting properly in header, and pinched o-ring.

Module sitting on o-ring

Module properly installed in header

Pinched o-ring of module not properly installed

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i) Loosely attach stainless steel clamp half sections such that there is some resistance, but still movable with slight pressure. If end cap is correctly oriented, then clamp half sections should fit easily over end cap and shell. Attach bolts, washers, and nuts. Use wrenches to completely tighten upper and lower clamps. Ensure the clamps are placed perpendicular to the direction of the headers, see Figure 17. This is important for step 6f below when using the ratcheting straps.

Figure 17: Bolt positions shown perpendicular to direction of the headers.

j) Repeat steps in point 5 for all modules. See Figure 18 for a set of

completed installation up to step 5.

Figure 18: Modules installed and completed up to step 5.

6. Once modules are installed, it is now time to connect and install the top

headers.

SAFETY NOTE: MAKE SURE MODULES ARE SECURED BEFORE

MOVING ON.

a) Repeat step 4 to assemble top headers.

Bolts perpendicular

to header

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b) You will need to install all concentrate adaptors into the top header as

shown in Figure 19.

Figure 19: Concentrate adaptors installed on Cube Headers for top of module.

c) If more than 6 – 7 headers need to be connected and no mechanical

lifting device is available, it will be required to again create 2 banks and

lift the headers on to the module to make middle connection instead of

on the floor or frame as shown in step 4f.

d) Once all the top cube headers are connected, the header must be

positioned into place. Place the headers such that the concentrate

adaptor is resting on the module and the header is a mirror image of the

bottom header. See Figure 20 for an example.

Concentrate adaptor

installed

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Figure 20: Top and bottom header should be a mirror image of each other.

e) The concentrate adaptors will then need to be placed inside the diffuser

central port for each module. See Figure 21. This may require for the

module to be adjusted slightly to align the concentrate adaptors. When

done properly all modules should sit flush with the headers. NOTE: It is

important that the bottom clamps are not tightened to ensure that the

modules can be moved slightly if necessary. It is best to start on one

end and place all concentrate adaptors into the module such that the

header will slowly come down.

SAFETY NOTE: MAKE SURE TO AVOID PINCHING FINGERS OR HANDS BY

KEEPING HAND CLEAR FROM BETWEEN MODULE AND HEADER AS

HEADER MAY FALL AT ANY TIME.

Top header is mirror image of bottom header

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Figure 21: Picture on left shows gap between header and module as concentrate adaptor and diffuser

central port are not properly aligned.

f) When headers are properly aligned, it is time to install headers. To do

so, use ratcheting straps on every other module. You can see in Figure

22 the straps are hooked onto the clamps. Ratchet straps down as

evenly as possible such that the header comes straight down to avoid

pinching o-rings. NOTE: Ensure all large o-rings are lubricated properly

to avoid pinching o-rings. Non-lubricated o-rings will have a higher

propensity to pinch.

SAFETY NOTE: THERE MAY BE A GREAT DEAL OF TENSION ON THE

STRAPS. WEAR PROPER SAFETY GLOVES, GLASSES, AND PPE TO AVOID

INJURIES. CAREFULLY RELEASE TENSION AFTER TOP ROW OF CUBE

HEADERS ARE IN POSITION

Figure 22: Ratcheting straps on every other module to pull down Cube Headers.

Concentrate

adaptor

Diffuser central port in module

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g) Install and tighten all half shell clamps once headers are in place both

on top and bottom.

7. Once all modules and headers are installed, connect the row end plugs and

adaptors. See Figure 1 and 2 and point 4 in the “General Guidelines and Rack

Design” above. Contact Hydranautics for row drawings if necessary.

8. Slowly pressurize the system and check for connection leaks. The system

should be pressurized to 30 psi (2 bar) or 1.5 times the regular feed pressure

of operation, maximum of 73 psi (5 bar) at 68°F (20°C). NOTE: Pressure rating

derates as temperature increases. Please contact a Hydranautics

representative if there are any questions about the pressure limits.

9. Once the modules are loaded, if they will not be put into service immediately,

the modules should be filled with a preservative solution. Please follow TSB

331, Storage In-Situ procedures.

Hydranautics

401 Jones Rd. Oceanside, CA 92058 Tel: (760) 901-2500 Fax: (760) 901-2578

email: info@Hydranautics.com